Hilux Surf KZN130 won't start

[bronx89]

No idea what the heck happened. Muriwai on Sunday, everything was fine, did some water works but nothing major. Drove home. Parked it. Went out about an hour later and rinsed it then took it to the car wash cause my water blaster is broke, came back home, and this morning it wouldn't start.

Engine won't even turn over. Get all the usual dash lights incl. glow plug light and I turn it to start it and just get a click. Batt's are good (both new). Didn't do anything weird on Sunday so I have no clue why it would have all of a sudden died.

Anyone struck this before? With it not even turning over, but still getting normal dash lights, can anyone narrow it down to anything?

Don't have time for a good look until weekend. Have had a quick look at under bonnet fuses, all look ok. Haven't had a check of the in cabin ones yet.

Idea's?

[ChurchurDan]

Sounds like a starter fault. If water gets into the solenoid the plunger can stick into the housing. Also they are bad for solenoid contacts.
If you get a loud clonk from the starter it is the contacts.
If you only get a click from the start relay check for power at the small wire on the starter, if you have power there when the key is turned to start it is something else in the starter. Either way the starter is coming off.
If you have no power at the start wire check the start relay.

[bronx89]

Thanks mate, yep had given the starter a bit of a smack with a hammer thinking it could be a stuck solenoid but didn't do the trick.

Will test the power to the starter hopefully this week or in the weekend and post up what I find.

Thanks again

[Mattman]

Possibly just the start wire come off/blown off the starter if you pressure washed it.

Matt

[bronx89]

Didn't pressure wash it this time, no water blaster, went through a car wash (automated one so no under-bonnet)!

Now I do see a tiny little wire and plug that is loose on starter motor side but up quite high in the engine bay off of the loom next to the head (passenger side) - haven't noticed this particular one before but there are a small number of plugs not being used/plugged in that I've noticed before so not sure if this ones new.

I've taken the bash plate off and got someone to try and crank it whilst I have an ear out, definitely get an audible click from a relay somewhere and also a sort of click/clunk directly from the starter motor/gearbox area.

Solenoid contacts? Where is it/are they? I can't even see that small wire as mentioned in first response.

[Mattman]

The solenoid is usually directly on top of the starter itself and should have a direct positive feed from the battery and a smaller signal wire from the ignition.

[bronx89]

Is the solenoid where the contacts you are talking about are? And is the solenoid a rectangular shaped plastic box that's connected to the starter motor with a nut at one end? It's on the side (sort of underneath) of the starter motor - not on top though - is this the wrong thing?

If I am looking at the right thing, what do I do with the solenoid to fix it or unstick the contacts? Or does it need to be replaced?

If anyone has a pic that'd be great

Thanks again for the help and let's hope it's just this solenoid!

[SamLogan]

The solenoid is inside the sort of rectangle with a triangle on top shaped bit that runs along the side of the starter. If you hear a clonk then it is likely that the contacts inside are stuffed and it is just a unfortunate consequence. If you can't hear a clonk from the starter then it is the starter relay. The ignition doesn't have the ability to drive the start solenoid. I believe the starter relay is by the fuse box on the drivers side in the engine bay. its quite big.

Sam

[bronx89]

If I put my hand on the starter and gearbox I can feel a sort of click/clonk (metal on metal but not heavy heavy) and also hear the relay click up top.

If the contacts are stuffed can they be cleaned up or does the solenoid need to be replaced? Do you know how much new ones go for? Or are second-hand ones all good?

Yep I know the relay you're talking about by the fuse box, on it's own metal bracket just beside fuse box right.

[truckingood]

if you can feel/hear a click at the start motor it probably wont be relay, sounds very much like the solenoid has gone and just one of those things

[bronx89]

Sweet - hope so, thanks mate. Can the contacts be cleaned/fixed or do I need a new solenoid?

If anyone has a photo of the solenoid on the starter that'd be great so I'm sure I'm looking at the right thing.

Are they two images accurate? Or are they from an LN130 and different?

Right one:

Contacts in solenoid (not what I thought the solenoid was!):

==============
EDIT

Found two write-ups (one with pics) on starter removal so will do that this weekend hopefully and have a look at contacts, if stuffed will buy a contact replacement kit and replace them and seal it up real good. Let's hope it is just the contacts and that it's blatantly obvious it is them once I can see them!

[ChurchurDan]

Your starter will be very similar to the one on the right. The contacts and plunger can be brought from an auto sparkie the contacts are about $15 and plunger about $25. I normally strip the whole starter and do the bearings as well especially if it has been wet.


Edit, dont use any sealant on your starter it does not help, if anything it helps trap moisture inside.

[bronx89]

Your starter will be very similar to the one on the right. The contacts and plunger can be brought from an auto sparkie the contacts are about $15 and plunger about $25. I normally strip the whole starter and do the bearings as well especially if it has been wet.


Edit, dont use any sealant on your starter it does not help, if anything it helps trap moisture inside.

Thanks for the heads up. Planning to take it out after work tonight then just have to source the parts to replace contacts tomorrow. Then put it back in Sat/Sun and have it ready for work Monday.

Are contacts and plunger generic(ish)? i.e. would any auto-sparky have them? Also is the plunger necessary too?

[ChurchurDan]

The plunger is the other half of the contacts so it needs to be replaced as well.
Any auto sparkie should have them (we do) as they are common as mud to replace.

[Mattman]

Definitely worth doing the bearings in there as well - bearings are cheap as.

If you have the starter out and apart easiest way is to take it to a sparky and get new bearings put on and the contact parts unless you have a bearing puller.

Matt.

[bronx89]

All sorted. New contacts and plunger and a good clean and she's good as new. Wish I'd seen that bearing post earlier would have done that too while it was out!

[Mattman]

Glad to here you got it all sorted. Now you know how to get it in and out doing the bearings at some other stage won't be a drama

[GNTONC]

Found two write-ups (one with pics) on starter removal

do you have a link ? need to take my starter out as well, thanks.

cheers,
steve

[bronx89]

Haha yea will leave that til it has to be done.

I just copied and saved the text not the link but I'll put them into word docs and attach or upload and give link to them for you

[bronx89]

Here you go. Note they mention about 5 hours I think in total but I had mine out in 1.5 hours and back in in 1. Recommend taking all the intake piping and filter etc. out from passenger side and using cable ties to get all the cables and hoses out of the way to make a hole to get it out the top. Good luck getting the top starter motor bolt/nut off - have fun!


1KZ-TE KZN130 Hilux Surf Starter Motor Removal

1KZ-TE KZN130 Hilux Surf Starter Motor Contacts Replacement‏

[GNTONC]

thank you, great help

cheers,
steve